Raw materials ordering system

ABSTRACT

This invention relates to a production system for retail goods which is intended for timely collection of accurate sales information from retail outlets and flexible production of goods in accordance with the same information, and comprises a retail sales information collecting means, a production quantity setting means for determining a production quantity according to the information so collected, a directing means for directing the preparation and production of raw materials according to the determined production quantity, and a production means for producing the determined production quantity according to a direction to produce. Also provided is a raw materials ordering system, which determines production quantities of raw materials in accordance with production plans for ensuring flexible production of the products without the disadvantage of carrying excessive inventories and for economical and efficient control and supply of raw materials. As such, the system comprises an order quantity determining means for setting or modifying daily required quantities of raw materials in response to setting or modification of daily production plans and determining order quantities according to raw material attributes, inventories, order backlogs, in-process order quantities and the required quantities of raw materials and a data input processing means for modifying the raw material inventory quantities upon receipt of raw material acceptance information. Furthermore, another type of the raw material ordering system disclosed in this application can be employed for those raw materials that require processing after placement of an order.

This application is a Divisional application of application Ser. No.08/650,054, filed May 16, 1996, (pending), which is a Continuation ofU.S. patent application Ser. No. 08/422,976, filed Apr. 17, 1995(abandoned), which is a Continuation of U.S. patent application Ser. No.07/692,425, filed Apr. 29, 1991 (abandoned).

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to a production system for retail goodssuch as beauty products and more particularly to a production systemwhich receives sales information from retail outlets timely and withaccuracy and manufacture said goods with flexibility.

The invention relates, in another aspect, to a raw material orderingsystem by which orders for raw materials necessary for the production ofproducts can be placed with flexibility and economically, and thusinsures timely procurement of raw materials without the disadvantage ofcarrying excessive raw material inventories. This raw material orderingsystem may be employed in conjunction with or independently from saidproduction system.

2. Prior Art

Production Systems for Goods Sold Over Retail Counters

In manufacturing a product for marketing, the manufacturer generallydetermines the quantity to be manufactured according to a marketing planinitially and instructs its factory to produce that quantity, and asneed arises, they instruct the factory to carry out additionalproduction.

However, such a production system is dangerous to the so-called fashionmanufacturer which must launch a new product as often as, say, once ayear and is specializing in fashion articles with limited market lives.Assuming that such a manufacturer drafted a merchandizing plan,manufactured an article accordingly and introduced it to the market andthe articles was accepted by consumers better than expected and sold outsoon. Then, deficiencies occur at retail outlets and the manufacturerloses many sales opportunities. Assuming, conversely, that themanufacturer mapped out a grandiose campaign but the market was notready to accept their product. Then, too many articles remain unsold andthe manufacturer must carry large stocks to be somehow liquidated.

To solve these problems, many manufacturers have so far explored intobetter methods for predicting potential demands. Thus, they try toovercome the problems by predicting demands from the past salesperformance of similar products and determining apparently appropriateproduction scales. However, when the article to be manufactured is anentirely new product, it is extremely difficult for the manufacturer toprognosticate the consumer acceptance, ascertain the trend in thepotential competitors, or predict the effect of a marketing campaign.Moreover, since weather may be a major factor affecting the sale ofproducts, demand prediction has its own limits and every one in theindustry today is aware of the great risk of relying on such prediction.

Raw Material Ordering System I

While different industries have been using somewhat different systemsfor the procurement of raw materials, the average approach is that whichis known as the fixed point-fixed quantity ordering system.

According to this fixed point-fixed quantity ordering system, a safestock level is predetermined for each raw material and when the rawmaterial inventory on hand has decreased to this critical stock level, asignal is given for placing a new order. This system is predicated onthe principle that the manufacturer should carry a reasonable stockpileof any raw material that is required to be certainly on the safe side.This is an expedient and optimal system for industries where stableproduction is the rule rather than the exception.

However, the fixed point-fixed quantity ordering system does not workwell and entails too large economic losses in industries where manykinds of products are manufactured in small lots and particularly wherethe dependency of any raw material on the production scale of theproduct is large. Thus, if a plurality of product items share aplurality of raw materials in common and such product items can bemanufactured merely by altering the combination of such raw materials,the fixed point-fixed quantity ordering system can be employed withadvantage. However, if, for example, three product items A, B and C haveone raw material a in common, the safe stock level of a, viz. thecritical point for this raw material, will then be set at the maximumquantity required for the production of all the three product items,with the result that the safety stock level of that raw material isexaggerated of necessity and, hence, chances are that the manufacturerwill have to carry an excessive raw material inventory.

To overcome the above disadvantage, a raw material ordering systemcalled MRP (the acronym of Material Requirements Plan) has for some timebeen in use. This is a system such that an order for any raw material isplaced in the quantity just necessary for the production of a given lotsize of each product item and is intended to preclude the disadvantageof carrying an excessive raw material inventory.

As all the raw materials for each product item are assorted as apackage, this system is convenient, indeed, but has the problem ofrigidity. Thus, since the raw material a is earmarked for the productionof item A only and no diversion of raw material a is made for theproduction of item B even if an instruction to produce B is entered, andthe production of B must begin only after procurement of raw material afor B. Since the raw materials, a, b, c . . . have been packaged innecessary amounts for the production of item A, the diversion of rawmaterial a from this package will result in a virtual waste of the otherraw materials b, c . . . .

Raw Material Ordering System II

Furthermore, the raw material ordering system MRP involves particulardifficulties and is disadvantageous when the raw materials call for longlead times between placement of an order and actual receipt of the rawmaterials. An example of such raw materials is bottles of cosmetics.Each manufacturer of cosmetics employs its own bottles with its ownshape, configuration, color, and ornamental design. When a manufacturerof cosmetics places an order for bottles of a particular type, amanufacturer of the bottles then molds the bottles, doessurface-finishing, and print brands and other characters and designs ifany on the surface thereof. Thus, for placing an order for a rawmaterial with a lead time of 3 months, it is of course necessary thatthe production scale as of 3 months ahead must have been determined butit is very difficult and even dangerous for manufacturers in the fashionand equivalent industries to predetermine a production size as of manymonths ahead.

Therefore, there has been proposed a still another system, viz. apreliminary ordering system in which the necessary quantities of parts,that is to say the amounts of consumption of parts, are predictedindependently of the production of a finished product and thesequantities of parts are arranged to be available beforehand. Accordingto this system, the necessary production activity can be started as soonas a manufacturing instruction is received but the manufacturer mustmaintain constant inventories of parts at all times and, particularlywhere the variety of production items is large, must maintain aproportionally increased total inventory of raw materials.

Furthermore, raw materials and particularly containers and the like arefed to the production line only after passing through a plurality ofprocesses such as surface and other treatments (factory) and assembling(factory), with the result that various forms of inventories are carriedin the respective processes. In such a situation, it is very difficultto keep a constant tab on which process stage is carrying what size ofinventory and this was near to impossibility particularly where thecontainer, for one, is procured from a series of container manufacturersand finishers. For this reason, the manufacturer in such cases placesorders for raw materials for each production job without a clear pictureof the inventory, with the result that they will have to carry a fairlylarge total inventory of raw materials.

SUMMARY OF THE INVENTION

The Production System for Retail Goods

The present invention has been developed to overcome the aforementioneddisadvantages.

It is, therefore, a first object of the present invention to provide anideal production system, which takes in sales information from retailoutlets timely and with accuracy and manufactures products withflexibility in quick response to the sales information, thus making itpossible to supply the market with any product when it is needed and inthe quantity needed.

To accomplish the above object, the production system for retail goodsin accordance with the present invention has the following constitution.Thus, this system comprises a retail sales information collecting means,a production quantity setting means for determining a productionquantity according to the sales information collected by thefirst-mentioned means, a directing means for directing the preparationand production of raw materials according to the production quantitydetermined as above, and a production means for producing the determinedproduction quantity in accordance with the direction.

In the above arrangement, as sales information from retail outlets aretransmitted by said retail sales information collecting means to saidproduction quantity setting means, the production quantity is setimmediately.

Then, this production quantity data is fed to said directing means fordirecting the preparation and production of necessary raw materials andthe production means receiving a direction to produce from saiddirecting means performs the production of the determined productionquantity.

As mentioned just above, the production system according to the presentinvention sets a production quantity in response to sales informationfrom retail outlets, directs the preparation and production of rawmaterials necessary for production of the set production quantity andperforms the production of the same quantity, thus making it possible toproduce any product that sells when it is needed and in the quantitythat is certain to be sold.

Therefore, all the problems encountered in the past, such asdeficiencies in stocks at retail outlets and the consequent loss ofsales opportunities or excessive accumulation of inventories can beobviated and an ideal manufacturing system can be established.

Preferably, it is so arranged that said retail sales information iscollected from a plurality of sample stores or departments and that saidproduction quantity setting means comprises a scale-up estimatingroutine for scaling-up of the retail sales information and a demandforecast routine for predicting the demand according to the scale-upestimate. Such a construction is conducive to a more accurate setting ofproduction quantity.

Furthermore, said production means is preferably provided with anautomatic switching function for automatically changing the powers etc.of the components of production equipment in accordance with directionsto produce. As the production means is so constructed, it is possible toestablish a production system which is quick to respond to directions toproduce without requiring switching of parts, for instance.

For directing or ordering the preparation and production of rawmaterials required in said production system for retail goods, one mayemploy Raw materials ordering systems I and II hereinafter explained.Raw materials ordering system I is to be used in connection with thoseraw materials which do not require special processings after placementof an order, such as material substances to be mixed to producehair-lotions. Raw materials ordering system II is to be used for thoseraw materials which require various processings after placement of anorder, such as containers of cosmetics.

Raw Material Ordering System I

It is a second object of the present invention to provide a raw materialordering system which is flexible enough to timely respond to productionneeds without carrying an excessive stock of raw materials and,particularly in industries where many items are produced in small lots,enables an economical and effective control and supply of raw materialswhich are otherwise complicated and time-consuming. In other words, thepresent invention provides a "raw material mixing system" wherein a rawmaterial prepared for producing one item is diverted for producinganother item when a necessity of producing additional number of productsof such another item emergently arises.

To accomplish the above object, the raw material ordering system of thepresent invention has the following constitution. This system, whichdetermines the order size of each raw material according to a productionplan for a product, comprises an order quantity determining means whichsequentially sets or modifies the required quantities of raw materialsfor each day in accordance with the daily production plan or changes inthe production plan and determines the order size in accordance with theattributes, inventories, order backlogs and in process quantities of theraw materials and said required quantities of raw materials and a datainput processing means which modifies said inventory quantities inresponse to raw material acceptance information and modifies saidproduction plan and raw material inventory quantities in response toproduction data.

In the above arrangement, the required quantities of respective rawmaterials are set in accordance with the day-to-day production plan andthe aforesaid required quantities are updated every time a change ismade in the production plan.

Then, the order size is determined, and an order is placed, withreference to the raw material attributes, such as standard lead time,supply quantity, safe stock level, etc., current inventory, orderbacklog, in-process quantity and required quantity of the raw materialso that the respective raw materials can be made available in amountsjust necessary and sufficient for current production needs without thedisadvantage of placing an unnecessary order.

Furthermore, as the production plan and raw material inventory valuesare updated automatically in accordance with raw material acceptancedata and production data, a flexible raw material ordering systemself-adapting to the flow of raw materials can be established.

Thus, the raw material ordering system of the present invention permitsplacing orders for raw materials which are commensurate with the dailyproduction plan. The required quantities of raw materials are set inresponse to every change in the production plan for a given day, andbased on the required quantities so set, as well as on the attributes,inventory levels, order backlogs and in-process quantities of respectiveraw materials, the optimum order sizes are determined so that necessaryraw materials can be procured when needed and in appropriate quantities.

Since the raw material inventory data and the daily production plans areautomatically updated upon receipt of raw material acceptance data andproduction data, the correct order sizes can be determined for meetingproduction needs without the risk of carrying excessive raw materialinventories and, particularly for manufacturers who produce a largevariety of products in small lots and, as such, should otherwise gothrough complicated ordering procedures, can now easily place orders forthe necessary raw materials at the right time in the quantities justneeded.

Furthermore, it is preferable to arrange said data input processingmeans so that the order backlog data is updated in response to the inputof raw material order acknowledgement and acceptance data and that thein-process data be also updated in response to the input of said (orderacknowledgement data.

Raw Material Ordering System II

It is a third object of the present invention to provide a raw materialordering system which controls raw material inventories in all formsaccording to processes and permits placing orders for necessary rawmaterials when needed and in the quantities needed, or at optimum times,without the disadvantage of carrying excessive inventories in therespective processes. This system is for those raw materials whichrequire processings after placement of an order.

To accomplish the above object, the raw material ordering system of thepresent invention has the following constitution. This system, whichplaces orders for the necessary raw materials comprises a raw materialhistory memory means which, for any raw material undergoing variousprocesses before it attains its final form, memorizes the relationshipof the condition at feeding to each process with the condition atcompletion of the process, a raw material inventory register means whichdetermines and registers the inventory quantity of each raw material, aproduct constitution memory means which memorizes the raw materialsconstituting each product and the required quantities thereof, a rawmaterial demand setting means which, for the necessary raw materials,determines the raw material demand quantities for respective processesretroactively from release to feeding in each process by reference tosaid raw material history memory means, and a raw material orderprocessing means which issues an order for any raw material to eachprocess in accordance with the raw material demand quantity set by saidraw material demand setting means and the raw material inventoryquantity registered in said raw material inventory register means.

In the above arrangement, the relationship between feeding and releaseof each raw material undergoing various processes such as working,assembling, etc. are memorized as raw material history information.Therefore, once a scheduled marketing quantity is set for a givenproduct, the required quantities of raw materials at each process levelcan be determined by tracing the flow back from the finished product toeach necessary raw material and thence to the form of the same rawmaterial at feeding to the process for conversion to the form suited forrelease.

Since, in this manner, an order can be issued to each of the processesfor any raw material in the corresponding form or condition, therequired raw materials can be procured when needed and in the quantitiesneeded without the risk of carrying unnecessary raw materialinventories.

Thus, in accordance with the raw material ordering system of the presentinvention, since ordering can be made on a process-by-process basis orin accordance with the form of each raw material at each process levelby reference to the history of the raw material, viz. finishing,assembling, etc. (factory) up to the final raw material, the risk ofcarrying an excessive inventory can be avoided and the required rawmaterials can be made available when needed and in the quantitiesneeded.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overall block diagram showing an embodiment of theproduction system for retail goods in accordance with the presentinvention;

FIG. 2 is a diagram illustrating the data structure of a productcharacteristics data table;

FIG. 3 is a schematic view illustrating an example of productcharacteristics classification in the table of FIG. 2;

FIGS. 4A through 4E each is a diagram showing the data structure of asampled outlet characteristics data table;

FIGS. 5A through 5B each is a diagram showing the data structure of ademand forecast data table;

FIG. 6 is a flow chart showing the action of a demand forecast routine;

FIG. 7 is a diagram showing the sales course pattern of a product;

FIG. 8 is a diagram showing the data structure of an inventory datatable;

FIG. 9 is a flow chart showing the action of a production quantitydetermining routine;

FIG. 10(a) through (d) each is a diagram showing the data structure of araw material data table;

FIG. 11 is a flow chart showing the action of a raw material orderingroutine;

FIG. 12 is a flow chart showing the action of a production means controlroutine;

FIG. 13 is a diagram showing the data structure of a drive output datatable;

FIG. 14 is a diagram explaining the production system in a productionroutine;

FIG. 15 is a view showing the overall construction of a raw materialordering system as an embodiment of the invention;

FIGS. 16 through 19 are diagrams showing an inventory data table, aproduction plan data table, a production plan modification transfer datatable and a required quantity data table, respectively;

FIG. 20 is a flow chart showing steps in an initial setting routine;

FIG. 21 is a flow chart showing steps in a production plan settingroutine;

FIG. 22 is a flow chart showing a required quantity setting routine;

FIG. 23 is a diagram showing a product constitution data table;

FIG. 24 is a flow chart showing steps in a production plan modifyingroutine;

FIG. 25 is a flow chart showing steps in a required quantity modifyingroutine;

FIGS. 26A and 26B are flow charts showing steps in an order quantitydetermining routine;

FIGS. 27 through 29 are diagrams showing a raw material attribute datatable, an order course data table and an order backlog data table,respectively;

FIG. 30 is a flow chart showing steps in an order acknowledgement datainput processing routine;

FIG. 31 is a flow chart showing steps in a raw material acceptable datainput processing routine;

FIG. 32 is a flow chart showing steps in a production data inputprocessing routine;

FIG. 33 is a view showing the overall construction of another rawmaterial ordering system embodying the invention;

FIGS. 34 through 39 are data tables in the same embodiment;

FIG. 40 is a flow chart showing steps in a parts inventory calculatingroutine I;

FIG. 41 is a flow chart showing steps in a parts inventory calculatingroutine II;

FIGS. 42 through 46 and 48 are views showing data tables in the sameembodiment;

FIGS. 49A through 49D are explanatory diagrams showing the same datatables substituted by factual values;

FIGS. 50 and 51 are views explaining the processessing of values appliedin FIG. 49;

FIG. 52 is a flow chart showing steps in a parts ordering routine;

FIG. 53 is a flow chart showing steps in a parts acceptance routine;

FIG. 54 is a flow chart showing steps in a parts releasing routine;

FIG. 55 is a view showing a production plan data table; and

FIG. 56 is a flow chart showing steps in a production planning routine.

FIGS. 57 and 58 respectively show examples of production means havingdrive units and control routines.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A Production System for Retail Goods

FIGS. 1 through 14 are views illustrating an embodiment of theproduction system linked to retail sales in accordance with the presentinvention. As shown, this system comprises a retail sales informationcollecting means 1, a production size setting means 2, a directing means3 for directing the preparation and production of raw materials, and aproduction means 4.

The retail sales information collecting means 1 comprises a plurality ofpoint-of-sale (POS) terminal units 1a, 1b, 1c . . . installed atdifferent retail outlets and a public communications line network 11connecting said POS terminal units 1a, 1b, 1c . . . with a host computerH. These POS terminals 1a, 1b, 1c . . . each memorizes the product namesand the quantity of each product sold and transmits the storedinformation to the host computer H daily at a fixed hour of the day.

These POS terminals 1a, 1b, 1c . . . are not installed at all the retailoutlets for any given product but are installed at sampled outletsrepresenting a given percentage of the total of such retail outlets.These sample outlets are selected from among the volume-selling outletsso that the system may receive sales information more efficiently.

The production size setting means 2 includes a scale-up estimatingroutine 5, a demand forecast routine 6 and a production size determiningroutine 7.

The scale-up estimating routine 5 receives sales information from saidplurality of POS terminals 1a, 1b, 1c . . . through said publiccommunications line network 11 from time to time as input data. In thisscale-up estimating routine 5, a scale-up estimate is obtained by meansof the following equation (1). Scale-up estimate= ##EQU1##

The manner of the above estimation is now described using an example.

FIG. 2 shows an example of the product characteristics data table 51connected to the scale-up estimating routine 5. Here, for each ofproducts A, B, C . . . X, the product classification, priceclassification, consumer age classification and merchandisingclassification data are stored.

FIG. 3 shows the particulars of each of the above four classifications.The product classification comprises six classes, namely foundationcosmetic, make-up cosmetic, shampoo & rinse, perfume & cologne, cosmeticsundry, and men's cosmetic as represented by the numerals of 1 through6, respectively. The price classification comprises five classes of low,medium-low, medium, medium-high, and high. The consumer age distributioncomprises five classes, namely low, intermediate between low andaverage, average, intermediate between average and high, and high asrepresented by numerals 1 through 5, respectively. The merchandisingclassification comprises five classes, namely display sale, ratherdisplay sale, equivocal, rather counseling sale, and counseling sale asrepresented by numerals of 1 through 5, respectively.

The above product characteristics data are determined at the stage ofproduct planning and as shown by entries in the column of product X inFIG. 2, the above-mentioned numerals are entered and stored forrespective classes of each classification. Thus, product X correspondsto Product Classification: 1 foundation cosmetic, Price Classification:2 medium-low, Consumer Age Classification: 5 high, and MerchandisingClassification: 2 rather display sale. Stated differently, product X is"a foundation cosmetic for consumers of advanced (high) age who spend inmedium-to low-price goods, which is merchandised by a method of salewhich is rather close to display sale."

FIG. 4(a) through (e) are views showing examples of sample retail outletcharacteristics data table 52. Here, for each of sample outlets S₁, S₂and S₃, data on the constitution and quantities of purchases during thepast year relative to those of all retail outlets are entered andstored. Thus, FIG. 4(a) is a data table 52a showing the relative salefor each of sample outlets S₁, S₂, S₃ . . . . FIG. 4(b) through (e) aredata tables 52b, 52c, 52d and 52e showing the product characteristic,price characteristic, consumer age characteristic and merchandisingcharacteristic, respectively, for each of sample outlets S₁, S₂, S₃ . .. . The aforesaid four characteristics in these data tables 52b, 52c,52d and 52e are represented in index numerals (1 if each is the same asthe national average) in correspondence with the four classificationsdescribed hereinbefore with reference to FIG. 3. Thus, for example, theindex for Product Classification: 1 foundation cosmetic is a₁ and theindex for Price Classification: 1 low is g₁ for sample outlet S₁.

Assuming that the quantities of product X sold at sample outlets S₁, S₂and S₃ are y₁, y₂ and y₃, respectively, the scale-up estimate forproduct X can be calculated by the following equation using the datafrom the aforementioned product characteristics data table 51 and thesample outlet data table 52. Scale-up estimate for product X= ##EQU2##

Thus, as the set characteristics of product X are Product Classification1, Price Classification 2, Consumer Age Classification 5 andMerchandising Classification 2 as shown in FIG. 2, the indexes forrespective characteristics shown in FIG. 4(b) through (e) correspond tothe above classifications, namely a₁, a₂ and a₃ for ProductCharacteristic 52b, h₁, h₂ and h₃ for Price characteristic 52c, p₁, p₂and p₃ for Consumer Age Characteristic 52d, and r₁, r₂ and r₃ forMerchandising Characteristic 52e.

The scale-up estimating routine 5 for calculating scale-up estimates isconnected to a demand forecast routine 6 which predicts demandsaccording to the scale-up estimates for respective products which areavailable from the scale-up estimating routine.

This demand forecast routine 6 performs a demand forecast in the stepsshown in the flow chart of FIG. 6 using the data stored in demandforecast data tables 61a, 61b shown in FIG. 5(a) and (b). Thus, storedin the demand forecast data table 61a of FIG. 5(a) are many sales coursepatterns (3 patterns 1 through 3 in the views) during 5 days followingthe launching of the product and the final sales estimates applicable tothe respective patterns 1 through 3. Similarly stored in the demandforecast data table 61b shown in FIG. 5(b) are the sales course patternsafter said 5 days, namely during 6 days after launching, as well asfinal sales estimates, for the product for which the pattern 2 was foundin said table 61a.

Then,

Step 1: Receiving of daily sales course data after launching of newproduct X from said scale-up estimating routine 5;

Step 2: Selecting the relevant demand forecast data table 61 accordingto the number of days after launching. Thus, if it is 5 days afterlaunching, the above table 61a for 5 days is selected and if it is 6days, table 61b is selected.

Step 3: Searching through the data table 61 selected in step 2 to find asales course pattern nearest to the pattern of sales course datareceived.

Step 4: Finding the final sales estimate for the product.

Step 5: Transfer ring the above estimate to a production sizedetermining routine 7 which is described hereinafter.

Thus, let it be assumed that the sales course pattern during 5 daysfollowing the launching of new product X is as shown in FIG. 7. Then,the demand forecast data table 61a shown in FIG. 5(a) is chosen as therelevant table and this table 61a is searched through for patternmatching. As a result, the sales course pattern of new product X isfound to approximate the pattern 2 stored in the table 61a and aforecast is made that at least a₂ units of this product X will beultimately sold. Then, the production size determining routine 7 isapproached accordingly. Since this final sales estimate is the lowestvalue selected by reference to the past sales performance, the veryselection of pattern 2 in the table 61a guarantees the sale of a₂ units.

The final sales estimate thus obtained in the demand forecast routine 6is fed to the production size determining routine 7 connected to thedemand forecast routine, where the production size is determined in thesteps shown in the flow chart of FIG. 9 using an inventory data table 71shown in FIG. 8. Thus, stored in the inventory data table 71 of FIG. 8are the inventory quantities and past additional production requestquantities for new products X, Y, Z . . . .

Thus,

Step 1: Retrieving the final sales estimate X for new product X fromsaid demand forecast routine

Step 2: Retrieving the inventory quantity z and past additionalproduction request quantity v for product X from said inventory datatable 71

Step 3: Assuming that the number of days after launching of new productX is n days, calculating the sales volume by scale-up estimation forthis period, ##EQU3## (yi is the sales volume by scale-up estimation onday i after launching)

Step 4: Calculating the required size of additional production of newproduct X by means of the following equation (3): ##EQU4## =requiredsize of additional

    production S                                               (3)

Step 5: Transferring this required size of additional production S tothe raw material ordering routine 8 and the control routine 4a for theproduction means 4, which are described hereinafter.

Step 6: Updating said additional production request quantity data in theinventory data table 71 with the result of the above calculation toprovide a new data.

The required size of additional production thus determined in theproduction size determining routine 7 is fed to the raw materialordering routine 8 and the control routine 4a for the production means 4simultaneously through the directing means (directing routine) 3connected to said determining routine 7 for timely production.

As the production is completed in production means 4, the inventory dataand past additional production request quantity data in the inventorydata table 71 are updated to provide new data. Thus, the currentinventory of new product X is Z units but upon receipt, from the controlroutine 4a of production means 4, of the information that the productionof additional production request quantity S of product X has just beencompleted, the inventory data for poduct X is updated to Z+S.

Meanwhile, the past additional production request quantity for thisproduct X is U units as of the present time but upon receipt of theinformation that the production of said required quantity S has beencompleted, the additional request quantity data is updated to U-S units.

A raw material ordering system will now be briefly explained makingreference to FIGS. 10 and 11. This system is substantially the same withwhat is stated in details in the section of Raw material ordering systemI below. In this case, a raw material ordering routine 1 I 18 in FIG. 1is employed. Instead of this raw material ordering routine, one mayutilize the system described in the section of Raw material orderingsystem II below. In this latter case, a raw material ordering routine II8' in FIG. 1 is used.

Thus, the raw material ordering routine I 8 using the raw material datatable 81 shown in FIGS. 10(a) through (d) calculates the quantities ofraw materials to be ordered in the steps shown in FIG. 11 and placeorders to a raw material procurement routine 9. This raw material datatable 81 comprises a product-classified raw material constitution datatable 81a shown in FIG. 10(a), a raw material-classified requiredquantity data table 81b shown in the same figure (b), a rawmaterial-classified inventory data table 81c shown in the same figure(c), and a raw material-classified acceptance schedule data table 81dshown in the same figure (d). Entered and stored in saidproduct-classified raw material constitution data table 81a are therequired quantities, per unit, of constituent raw materials α, β . . .for each of product A, B . . . X. For example, these data indicate thatp₁ units of raw material α are required for the production of 1 unit ofproduct X. Similarly entered and stored in the raw material-classifiedrequired quantity data table 81b are the quantities α₁, α₂, . . . α_(n)of each raw material required (to be used) on a day-to-day basis (1˜ndays). Stored in the raw material-classified inventory data table 81care the inventory data Zα, Zβ . . . for raw materials α, β . . . , whilethe acceptance schedule quantity data for raw materials α, β . . . on aday-to-day basis (1˜n days) are stored in the raw material-classifiedacceptance schedule data table 81d.

Thus,

Step 1: Receiving required additional production quantity S for newproduct X from said production size determining routine 7

Step 2: Receiving scheduled production day information j, with thecurrent day being taken as 0, from the production means 4

Step 3: Searching through the product-classified raw materialconstitution data table 81a to find the constituent raw materials forthis product X and the required quantities p₁, p₂ . . . thereof per unitof product X

Step 4: Multiplying the above required quantities p₁, p₁ . . . of rawmaterials per unit by the required additional production size data Sfrom said production size determining routine 7 to find the requiredadditional quantities of raw materials sp₁, sp₂ . . .

Step 5: Adding the required additional quantities of raw materials sp₁,sp₂ . . . to the respective required quantities aj, bj . . . forscheduled production day j in the raw material-classified requiredquantity data table 81b.

Step 6: Searching through the raw material-classified inventory datatable 81c to find the current raw material-classified inventory volumedata as of the current day.

Step 7: Calculating the excess or shortage on each of the following andsubsequent days for each raw material by means of the following equation(4) and designating the day on which a shortage occurs for the firsttime, that is to say when the aforesaid excess/shortage becomesnegative, as the delivery date. The order size at this time isdetermined by the following equation (5) and this order size data is fedto the raw material procurement routine 9. Excess or shortage of rawmaterial α on day k= ##EQU5##

Thus, it is found from the product-classified raw material constitutiondata table 81a that 3 p₁ units of raw material α is required for theproduction of 3 units of new product X, and in the rawmaterial-classified required quantity data table 81b, this requiredquantity 3p₁ is added to the initially required (scheduled to use)quantity aj of raw material α for scheduled production day j. In otherwords, aj+3p₁ units of raw material α is required on day j. This is setas the new aj. Then, assuming that the current inventory of raw materialα is Zα units, it is calculated that ##EQU6## units of raw material αwill remain on day k. Assuming that this value becomes negative for thefirst time on day k, this day k is regarded as the delivery date for rawmaterial α.

The production means 4, which receives a direction to produce from thedirecting routine 3 and performs the directed production, comprises aproduction unit 4b, which is a hardware, and a control routine 4a whichcontrols the production unit 4b according to said direction.

The production unit 4b has drive units 4c for setting and outputtingaction ranges, speeds and powers for respective machine units and thesedrive units 4c are controlled by said control routine 4a. And as shownby the flow chart of FIG. 12, a drive unit output data table 41 shown inFIG. 13 is searched through on receipt of a direction to produce forautomatic switching of respective drive units 4c. Entered and stored inthis drive unit output data table 41 are the output values of driveunits 1, 2 . . . for each of products A, B . . . Z.

Thus,

Step 1: Receiving a direction to produce product X from said directingmeans 3

Step 2: Clearing the output values memorized by respective drive units4c

Step 3: Searching through the drive unit output data table 41 for thisproduct X to determine output values for the respective drive units 4c

Step 4: Transmitting the output values to the respective drive units fortemporary memorization and start of the production of product X.

Furthermore, this production means 4 is constituted so as to immediatelyrespond to a direction to produce from said directing means 3. Thus, itis so arranged, as shown in FIG. 14, that the production line(production unit) 4b to which a direction for additional production ofnew product X will be issued is normally used for the production ofstaple products A, B and C (products such that if produced inanticipation, there is no risk of carrying large inventories) which arecomparatively long in delivery term and that when a direction foradditional production of new product X arrives from said directing means3, the production of staple products A, B and C is deferred in the ordermentioned to give priority to the production of this product X. Thus,for product X, the action from step 2 explained with reference to FIG.12 can be immediately commenced.

An example of the production means 4 is shown in FIG. 57, which is usedfor producing, for example, bottled lotions. The reference characters A₁to A₁₀ and A₁₁ denote drive units and a control routine respectively.

Bottles are taken out from a box at the unit A₁, examined at the unitA₂, and conveyed by the unit A₃. Cosmetic materials (lotion) is bottledby the unit A₄. And inner caps and outer caps are fastened by the unitsA₄ and A₅ respectively. The outer appearance of the bottles are thenexamined by the unit A₇. A few bottles are packed in a box at the unitA₈, a certain number of such boxes are packed in a larger box at theunit A₉, and furthermore a certain number of the larger boxes are packedin a still larger box at the unit A₁₀. These drive units are controlledby a control routine A₁₁.

Raw Material Ordering System I

FIGS. 15 through 32 show a raw material ordering system embodying thepresent invention. In this system, a raw material ordering routine I 8in FIG. 1 is used.

FIG. 15 is a view showing the overall construction of the raw materialordering system of the embodiment. As shown, this system comprises anorder size determining means A and a data input processing means B.

The order size determining means A comprises an initial setting routine101, a production plan setting routine 102, a required quantity settingroutine 103, a production plan modifying routine 104, a requiredquantity modifying routine 105 and a order size determining routine 106.

Connected to the initial setting routine 101 are an inventory data table107 shown in FIG. 16, a production plan data table 108 shown in FIG. 17,a production plan modification transfer data table 109 shown in FIG. 18and a required quantity data table 110 shown in FIG. 19, so that for thedata stored in these respective tables 107, 108, 109 and 110, initialsetting may be performed in the steps shown in a flow chart of FIG. 20.Thus, in the inventory data table 107 shown in FIG. 16, inventoryquantity data for respective raw materials are stored, while dailyproduction plan data for respective raw materials are stored in theproduction plan data table 108. The production plan modificationtransfer data table 109 is designed for effecting the transfer of datawhen a modification of data in the required quantity data table 110shown in FIG. 19 is made in response to modification of data in saidproduction data table 108 and its details are described hereinafter.

Stored in the required quantity data table 110 are the data representingthe required quantities of respective raw materials for respective days.

Step 1: Receiving an input of the current actual inventory quantity W ofraw material Ri

Step 2: Replacing the inventory quantity Zi for Ri in said inventorydata table 107 with W to provide a new value of Zi

Step 3: Confirming that all the above procedure has been completed forall raw materials. If the answer is affirmative, the sequence proceeds:

Step 4: Resetting all the production plan data Xij in said productionplan data 108 to zero.

Step 5: Resetting all the transfer data ΔXij in the production planmodification transfer data table 109 to zero.

Step 6: Resetting all the required quantity data Yig in requiredquantity data table 110 (made zero) to complete the initial setting.

Thus, the actual current inventory may not necessarily be in agreementwith the difference found by subtracting the used quantity from theinitial inventory data but some error due to breakage or the like ismore or less inevitable. Therefore, it is necessary to first correct allthe inventory data at the beginning processing. For the production plandata, production plan modification transfer data and required quantitydata, too, all the initial values are reset for starting from zero.

After such initial setting, production plan setting is carried out inthe production plan setting routine 102. This production plan settingroutine 102 is connected to said production plan data table 108 so thatproduction plan setting can be made in accordance with the flow chart ofFIG. 21. Thus,

Step 1: Receiving a production plan input X for day d for product Pi

Step 2: Substituting X for the production plan data which has beeninitialized to zero by said initial setting to provide a new Xid value

Step 3: Confirming that production plan setting has been completed forall products to complete the processing.

Then, the required quantities of respective raw materials in an initialstage are calculated in a required quantity setting routine 103.Connected to this required quantity setting routine 103 are saidproduction plan data table 108, required quantity data table 110 andproduct constitution data table 111 and the initial required quantitiesare calculated in the steps shown in the flow chart of FIG. 22. Storedin said product constitution data table 111 are the quantities ofrespective raw materials necessary for the production of one unit ofeach product.

Step 1: Retrieving the production plan size Xid for day d for product Pifrom the production plan data table 108

Step 2: Retrieving the required quantities Ci₁, Ci₂ . . . and Cin of rawmaterials for the production of one unit of product Pi from the productconstitution data table 111

Step 3: Multiplying Cij (j=1, 2 . . . , n) by said Xid to prepare Yid(j=1, 2 . . . , n) in the required quantity data table 110

Step 4: Confirming that the above procedure has been completed. Therequired quantity setting is thus completed.

The flow from initial setting from required quantity setting has beendescribed so far. Now, the flow for modifying the required quantity datain response to modification of production plan data is explained below.

Modification of production plan data is carried out in the productionplan modifying routine 104 in the steps shown in the flow chart of FIG.24. Connected to this production plan modifying routine 104 is not onlythe production plan data table 108 but also said production planmodification transfer data table 109 shown in FIG. 18. Thus,

Step 1: Receiving a production plan input X for day d for product Pi

Step 2: Retrieving the production plan data Xid for day d for product Pifrom the production plan data table 108

Step 3: Calculating the difference ΔX between X and Xid

Step 4: Replacing the Xid value with X to provide a new Xid value

Step 5: Retrieving the production plan modification amount ΔXid for dayd for product Pi from the production plan modification transfer datatable 109

Step 6: Adding said ΔX to this ΔXid to provide a new ΔXid value

Step 7: Confirming that there is no change in the other production plandata. The modification of production plan data is thus completed.

As the production plan data are thus modified, modification of requiredquantity data is automatically carried out in the required quantitymodifying routine 105. Connected to this required quantity modifyingroutine 105 are the production plan modification transfer data table109, product constitution data table 111 and required quantity datatable 110 and the modification of required quantity data is performed inthe steps shown in the flow chart of FIG. 25. Thus,

Step 1: Retrieving the production plan modification amount ΔXid for dayd for product Pi from the production plan modification transfer datatable.

Step 2: Retrieving the required quantities Ci₁, Ci₂, . . . Cin of rawmaterials for the production of one unit of product Pi from the productconstitution data table 111

Step 3: Retrieving the required quantities Y₁ d, Y₂ d . . . and Ynd ofrespective raw materials for day d from the required quantity data table110

Step 4: Adding the product of Cij (j=1, 2 . . . , n) multiplied by ΔXidto said Yjd (j=1, 2 . . . and n) to provide a new Yid value

Step 5: Resetting ΔXid to zero in the production plan modificationtransfer data table 109

Step 6: Confirming that all the above procedure has been completed. Themodification of required quantities is thus completed.

Thus, if a change is made in the production plan, modification of therequired quantity data table 110 is made through the production planmodification transfer data table 109 from the production plan data table108. For this reason, even if changes in the production plan take placein close sequence for one given product, the modification of requiredquantities can be easily carried out.

After the above setting or modification of required quantities of rawmaterials for each day, calculation of quantities to be ordered iscarried out in the order size determining routine 106.

Connected to this order size determining routine 106 are not only theinventory data table 107 and required quantity data table 110 but alsothe raw material attribute data table 112, the in-process order datatable 113 and the order backlog data table 114, and the calculation ofthe order size is performed in the steps shown in the flow chart of FIG.26.

FIG. 27 shows an example of said raw material attribute data table 112.As shown, stored in this raw material attribute data table 112 are thenames of suppliers of respective raw materials, standard lead times,daily supply quantities and safe inventory levels as data representingattributes of the respective raw materials. Furthermore, the in-processorder data table 113 shown in FIG. 28 and the order backlog data table114 shown in FIG. 29 contains daily in-process order data and orderbacklog data, respectively, for respective raw materials.

Step 1: Retrieving the standard lead time Ti, daily supply quantity Qiand safe inventory level Si for raw material Ri from the raw materialattribute data table 112

Step 2: Adding said standard lead time Ti to the current relative date dand setting the result as the designated delivery date T*. Thus, ininitial setting, the standard lead time as such becomes the designateddelivery date.

Step 3: Retrieving the inventory data Zi of raw material Ri from theinventory data table 107

Step 4: Retrieving the daily required quantities Yi₁, Yi₂, . . . and Yirof raw material Ri from the required quantity data table 110

Step 5: Copying said Yi₁, Yi₂ . . . and Yir to provide Y₁ *, Y₂ *, . . .and Yr*

Step 6: calculating the minimum k (k=T* , T*+1, . . . , r) thatsatisfies the following inequality (1) . . . using the above values##EQU7##

Step 7: Designating the smallest of the calculated k values as K andaltering the Yk* value using the following equation (3)

    Yk*=Yk*+Si                                                 (3)

Step 8: Determining k₁ and k₂ (k₁ =1, 2 . . . and r-1; k₂ =r, . . . , k₁+2, k₁ +1) which satisfy the following inequality (4) ##EQU8##

Step 9: Calculating D by the following equation (5) using the k₁ and k₂values determined as above ##EQU9##

Step 10: Provided that D<Yk₁ *, adding 1 to k₁. The sequence thenreturns to step 9. Provided that D≧Yk₁ *, effecting the followingchanges

(i) Yk₁ *=D

(ii) Yj*=Qi

(j=k₁ +1, k₂ +2, . . . , k₂)

Step 11: Checking to see whether the k₁ has reached r. If not,substituting k₂ for k₁ and repeating the sequence from step 8.

The modification of required quantity data is complete when k₁ hasreached r and this means a completion of the required quantity datatable 110.

Prior to proceeding to the next step, the above flow is explained usingspecific values for ease of understanding.

Step 1: Let it be assumed that the data on raw material R₁ in the rawmaterial attribute data table 112 are as follows.

Standard lead time T₁ =4 days

Daily supply quantity Q₁ =8 units

Safe inventory level S₁ =2 units

Step 2: Designated delivery day T*=T₁ =4

Step 3: In the inventory data table 107, the inventory quantity Z₁ ofraw material R₁ =23 units.

Step 4: From the required quantity data table 110, the current dailyrequirements of raw material R₁ are retrieved as shown in the followingtable.

    ______________________________________    Day    Raw material            1      2     3    4   5    6   7    8   9    10    ______________________________________    R1      5      8     6    10  4    7   9    4   2    6    ______________________________________

Step 5: Y₁ *=5, Y₂ *=8, Y₃ *=6, . . . , Y₁₀ *=6.

Step 6: Among k=T*, T*+1, . . . , 10, i.e. k=4, 5, . . . , 10, k=4 doesnot satisfy the inequalities because ##EQU10## However, k=5 satisfiesthe inequalities, thus ##EQU11##

Step 7: k=5, and Y₅ *=Y₅ *+S₁ =4+2=6. Therefore, the current setting Y₅*=4 is altered to Y₅ *=6.

Step 8: Search to find that k₁ and k₂ which satisfy the followingequality ##EQU12##

Step 9: ##EQU13##

Step 10: Since D=8≧Yk₁ *=6, set

(i) Y₃ *=8

(ii) Y₄ *=8

Thus, the settings Y₃ *=6 and Y₄ *=10 are respectively changed to 8.

Step 11: Since k₁ =3 and has not reached r=10, select k₁ =4 and repeatthe sequence from step 8.

Then, k₁ =6 and k₂ =7 are found and, as a result, the following changesare made in step 10.

(i) Y₆ *=8

(ii) Y₇ *=8.

After the above modification, the required quantity data table 110 is asfollows.

    ______________________________________    Day    Raw material            1      2     3    4   5    6   7    8   9    10    ______________________________________    R.sub.1 5      8     8    8   6    8   8    4   2    6    ______________________________________

Comparison of the above table with the pre-modification table shows thatthe quantity of 4 units on day 5 has been changed to the quantity of 6units, and the required quantity of 10 units on day 4 and that of 9units on day 7 have been advanced to day 3 and day 6, respectively,indicating that the data have been made compatible with the daily supplyquantity of raw material R₁, which data supplements the safe inventorylevel on a suitable timing.

Now, referring back to the flow chart of FIG. 26, the sequence from step12 is explained.

Step 12: From the in-process order data table 113, the daily in-processquantities fi₁, fi₂, . . . and fir of raw material R₁ are retrieved.

Stored in this in-process order data table 113 are the quantities of rawmaterials for which orders have already been placed but are yet to beincluded in the inventory quantities Zi.

Step 13: From the order backlog data table 114, the daily order backlogquantities gi₁, gi₂, . . . and gir of raw material R₁ are retrieved.

Step 14: The following equation (6) is calculated. ##EQU14##

Step 15: Provided that F>0 and ##EQU15## a negative order sheet isexecuted for fij>0 and the particular fij is reset to 0. Here, the orderof fij data to be thus processed begins with the one in which j isclosest to r, that is to say the last one.

Step 16: The following equation is calculated. ##EQU16## Provided thatF*>0, the order size is set to F* and an order sheet is printed. Then,fiT*+F* is calculated to set fiT*.

Step 17: Finally, it is confirmed that all the above processing has beencompleted for all the raw materials.

Now, the sequence beginning with step 12 following the aforesaid step 11is described in further detail.

Steps 12, 13: From the in-process order data table 113 and order backlogdata table 114, the daily in-process quantity and daily order backlogquantity data for raw material R₁ are retrieved as shown in thefollowing table. It should be noticed that the figures in the top rowrepresent the daily requirements of raw material R₁ as determined up tostep 11.

    ______________________________________    Day            1          2     3        4   5    ______________________________________    Yj*     5          8     8        8   6    f.sub.1 j            7          0     3        Omitted    g.sub.1 i            5          4     0        Omitted    ______________________________________    Day            6          7     8        9   10    ______________________________________    Yi*     8          8     4        2   6    f.sub.1 j            --         --    --       --  --    f.sub.1 j            --         --    --       --  --    ______________________________________

Step 14: The following equation is calculated. ##EQU17##

Step 15: Provided that F>0 and ##EQU18## it means that the order size isexcessive. Therefore, the f₁ j settings are changed to zero from theback, i.e. starting with day 10.

The result is assumed to be as follows.

    ______________________________________    Day    1      2      3      4    5    6    7    8    9    10    ______________________________________    Yj*  5     8      8    8    6    8    8    4    2    6    f.sub.1 j         0     0      0    0    0    0    0    0    0    0    g.sub.1 j         5     0      0    0    0    0    0    0    0    0    ______________________________________

Step 16: Since ##EQU19## and F*>0, the order size is set to 1, an ordersheet is printed, and f₁₄ is set to 1.

After the order size has thus been determined in the order sizedetermining routine A, the order sheet is issued and the data processingis carried out in the data input processing means B. This data inputprocessing means B comprises an order acceptance data input processingroutine 115, a raw material acceptance data input processing routine 116and a production data input processing routine 117.

Connected to the order acceptance data input processing routine 115 aresaid order backlog data table 114 and in-process order data table 113and the data processing is performed in the steps shown in the flowchart of FIG. 30.

Thus,

Step 1: Retrieving the data on the order quantity L and scheduleddelivery day d for raw material Ri from the order acknowledgement fromthe supplier of the raw material

Step 2: Retrieving the order backlog quantity gid for day d for rawmaterial Ri from the order backlog data table 114

Step 3: Adding the order quantity L to said order backlog quantity gidto set a new gid value

Step 4: Retrieving the in-process order quantities fi₁, fi₂, . . . andfir for raw material Ri from the in-process order data table 113.

Step 5: Searching for k which satisfies the following inequality (8)(provided, however, that fi₀ =0) ##EQU20##

Step 6-1: If there exists one,

(i) The fi₁, fi₂, . . . and fir values retrieved in step 4 are made 0,and

(ii) ##EQU21## is calculated and the result is set as a new fik value.

Step 6: If there is none, the initial order backlog quantity gid isreinstated and it is judged that there was an error in the input data.

Step 7: Confirming that there is no other order acknowledgement data.The input processing of order acknowledgement data is now complete.

Connected to the raw material acceptance data input processing routine116 are said inventory data table 107 and order backlog data table 114and the data processing is performed in the steps shown in the flowchart of FIG. 31. Thus,

Step 1: Receiving an acceptance quantity input U for raw material Ri

Step 2: Retrieving the inventory quantity Zi for raw material Ri fromthe inventory data table 107

Step 3: Adding the acceptance quantity U to said inventory quantity Zito provide a new Zi value

Step 4: Retrieving the order backlog quantities gi₁, gi₂, . . . and girof raw material Ri from the order backlog data table 114.

Step 5: Searching for k which satisfies the following inequality (9)(provided, however, that gi₀ =0) ##EQU22##

Step 6-1: If there exists one,

(i) gi₁, gi₂, . . . and gi (k-1) are set to 0, and

(ii) ##EQU23## is calculated and the result is set as a gik value.

Step 6-2: If there is one,

the initial inventory quantity value Zi is reinstated and it is judgedthat an error occurred in input data.

Step 7: Confirming that there are no other raw material acceptance data.The input processing of raw material acceptance data is now complete.

And in the production data input processing routine 117, using the datastored in the production plan data table 108, production datamodification transfer data table 109, inventory data table 107 andproduct constitution data table 111, which are connected thereto, theinput processing of production data is carried out in the steps shown inthe flow chart of FIG. 32.

Thus,

Step 1: Receiving a production data input V for product Pi

Step 2: Retrieving the production plan data Xi₁, Xi₂, . . . and Xir forproduct Pi from the production plan data table 108

Step 3: Comparing said production data V with ##EQU24##

If V is larger, V* is set to ##EQU25##

If V is smaller, V* is set to V.

Step 4: Searching for K which satisfies the following inequality (10)(provided, however, that Xi₀ =0) ##EQU26##

Step 5: Retrieving the daily increase/decrease value ΔXi₁, ΔXi₂, . . .and ΔXir for product Pi from the production plan modification transferdata table (9)

Step 6: Calculating ΔXij-Xij to provide a new ΔXij value (j=1, 2, . . ., k-1)

Step 7: Set Xij to 0

Step 8: Calculating ##EQU27## to provide ΔXik

Step 9: Calculating ##EQU28## to provide a new Xik value.

Step 10: Retrieving the inventory quantity Zi of product Pi from theinventory data table 107

Step 11: Retrieving the required quantities Ci₁, Ci₂, . . . and Cin ofraw material Ri for the production of one unit of product Pi from theproduct constitution data table 111

Step 12: Calculating the used quantity Cij×V of raw material Ri (j=1, 2,. . . and n) and subtract the result to provide a new Zj value.

Step 13: Confirming that there is no other production data to beinputted. The input processing of production data is now complete.

Thus, in the data input processing means B, updating of data isautomatically carried out according to the order acknowledgement data,raw material acceptance data and production data incomming in sequence.Therefore, the data in the tables such as the inventory data table 107,production plan data table 108 and required quantity data table 110 arealways reflecting flexibly the changes in the flow of raw materials andso on, thus eliminating the risk of placing orders without true needs.

Furthermore, since the required quantity of each raw material can beordered with certainty on a day-to-day basis, the risk of delay inproduction due to delays in receipt of raw materials can also beobviated.

Raw Material Ordering System II

FIGS. 33 through 56 show another embodiment of the raw material orderingsystem according to the present invention. In this case, a raw materialordering routine II 8' is used.

FIG. 33 shows the overall construction of the raw material orderingsystem of this embodiment as applied to the ordering for parts.

As shown, this system comprises a data register means XA, a parts demandsetting means XB, and a parts control means XC.

The data register means XA comprises a parts inventory register routine201, an in-process inventory register routine 202, a parts inventorycalculating routine I203, a parts inventory calculating routine II 204,a parts release data table initializing routine 205, a parts order datatable initializing routine 206 and a data table register routine 207.

The parts inventory register routine 201 is connected to a partsinventory data table 208 shown in FIG. 34 and the current actual partsinventory quantities are registered in this routine 201. Thus, since thetrue inventory quantity does not necessarily agree with the differencefound by subtracting the used quantity from the initial inventoryquantity data but contains some error due to breakage etc., it isnecessary to correct for the error, for example at the end of eachmonth. And when the current inventory quantity data of, for example,part code P is P units, this number is registered as R (real) inventoryof part code P in the parts inventory data table 208.

The in-process inventory register routine 202 is connected to anin-process inventory data table 209 shown in FIG. 35 and the in-processinventory quantity is registered in this routine 202. Thus, when thein-process inventory quantity of product A in process i is a units, theinventory quantity of A in process i in the in-process inventory datatable 209 is registered as a units.

After the registration of R inventory (real stock) in the partsinventory data table 208 and the in-process inventory quantity of eachproduct item in each process in the in-process inventory table 209, theV inventory (the stock at a given stage in the manufacturing process,such as surface treatment, assembling, etc.) and S inventory (cumulativestock) quantities are calculated in the parts inventory calculatingroutine I203 and the parts inventory calculating routine II204,respectively.

The above parts inventory calculating routine I203 is connected to saidparts inventory data table 208, a parts constitution data table 210 anda parts processing data table 211, which store parts historyinformation, a parts order data table 212 and a parts release data table213, and the V inventory of the parts is calculated in the steps shownin FIG. 40.

FIG. 36 shows the above parts constitution data table 210. Stored inthis table are the constitution data of the parts. The constitution dataare the data showing the relationship between the daughter part beforeassembling and the mother part after assembling as expressed in thenumber of daughter parts required for the constitution of each motherpart after assembling. Thus, referring to FIG. 36, the mother part Xconsists of ψ₁ units of daughter part U, ψ₂ units of daughter part V andψ₃ units of daughter part W. Stored in the parts processing data table211 are the processing data of respective parts as shown in FIG. 37. Theprocessing data mentioned above represent the relationship between thebefore-part prior to processing and the after-part after processing suchas a surface treatment. Thus, FIG. 37 indicates that the processing ofbefore-part P gives after-part Q and that the processing of this part Qas a before-part gives after-part T or U.

Stored in the parts order data table 212 are the order numbers andsuppliers, delivery terms, order quantities and acceptance quantities ofparts as shown in FIG. 38, while the parts release slip numbers,relevant manufacturers and release quantities of parts are stored in theparts release data table 213 as shown in FIG. 39.

Thus,

Step 1: Retrieving the current V inventory data P' for part code P fromthe parts inventory data table 208

Step 2: Determining the total release quantity Σh of part code P fromthe parts release data table 213

Step 3: Retrieving the mother part code of part code P from the partsconstitution data table 210

Step 4: Searching through the parts order data table 212 to find thequantity P₁ (acceptance quantity) of part code P delivered under themother part code assigned by conversion of the part code P to the motherpart code

Step 5: Retrieving the after-part code of part code P from the partsprocessing data table 211

Step 6: Searching through the parts order data table 212 to find thequantity P₂ (acceptance quantity) of part code P delivered under theafter-part code assigned by conversion of the part code P to theafter-part code.

Step 7: Calculating P'+Σh-P₁ -P₂ and setting the result as a new Vinventory P' of part code P in the parts inventory data table 208

Thus, at the time-point of delivery of parts of part code P as motherparts or after-parts, the corresponding quantity is not treated as theinventory of parts of part code P but dealt with as the inventory ofmother parts or after-parts so that only the data of parts which havebeen released as parts of part code P but not yet to be delivered asmother parts or after-parts is dealt with as the V inventory data ofpart code P. Thus, assuming that 100 units of part code P have beenreleased for processing and 50 units of after-part code Q of part code Phave already been received by an assembly line downstreams of theprocessing stage, the inventory quantity of part code P in theprocessing stage is registered as 50 units. In this manner, the quantityof parts currently remaining in the form of part code P as an inventorycan be clearly grasped. And as said 100 units of part P released forprocessing are sequentially subjected to processing and assembling, theychange form smoothly in the data along the line of flow, for example 50units of part P and 50 units of after-part Q at the moment, so that anaccurate and constant tab can be maintained on what forms (conditions)of inventory are existing in what quantities in respective stages ofproduction. Connected to the parts inventory calculating routine II204are said parts inventory data table 208, parts constitution data table210, parts processing data table 211 and in-process inventory data table209, as well as a product constitution data table 214, and the Sinventory (cumulative inventory) of the parts is calculated in the stepsshown in FIG. 41. Stored in said product constitution data table 214 arethe part codes, process codes and constituent numbers of parts necessaryfor respective products as shown in FIG. 42.

Thus,

Step 1: Retrieving the R inventory P and V inventory P' of part code Pfrom the parts inventory data table 208

Step 2: Searching through the parts inventory data table 208 and theparts constitution data table 210 or the parts processing data table 211to count all the quantities of part code P and setting the total countas P₁

Step 3: Searching through the in-process inventory data table 209, theproduct constitution data table 214 and the parts constitution datatable 210 or the parts processing data table 211 to count all thequantities of part code P and setting the total as P₂

Step 4: Calculating P*=P+P'+P₁ +P₂ and setting the result as the Sinventory P* in the parts inventory data table 208.

Thus, the parts bearing the part code P and those bearing variousderivative forms of the original part code P are all countedretrogradely to arrive at the cumulative inventory (S inventory) of partcode P.

Then, in the parts inventory calculating routine I203, the releasedquantity registered in the parts release data table 213 is counted as Vinventory, and in the parts release data table initializing routine 205,all the data in the parts release data table 213 are erased.

In the parts order data table initializing routine 206, the differencebetween order quantity and acceptance quantity in the parts order datatable 212 is set as the new order quantity, while the acceptancequantity is set as zero. The data registration processing up to thecurrent time is thus complete.

Then, in the data table register routines 207 and 207a through 207e, theregistration and modification of the product attribute data table 215,product constitution data table 214, parts constitution data table 210,parts processing data table 211 and parts attribute data table 216 arecarried out.

Stored in the product attribute data table 215 are the productclassification, launching dates of competitive brands, periods ofconcurrent sale with the competitive brands and the scheduled drop(discontinuation) data of each product as shown in FIG. 43. Thus, theproduct name A is entered and the aforesaid attribute data arerespectively registered or modified. The product classification is thedistinction of whether the sales of a product is to continue for morethan a predetermined time period after launching.

In the product constitution data table 214 shown in FIG. 42, too, theproduct name A is entered and the registration or modification of thepart codes constituting this product A, relevant process codes and thenumbers of constituent parts are effected.

In the product constitution data table 210 and parts processing datatable 211 shown in FIGS. 36 and 37, respectively, the mother part code Xor before-part code P/Q is entered and the registration or modificationof the daughter part code constituting the mother part code X and thenumber of constituting daughter parts or the after-part code of thebefore-part code P/Q are carried out.

Furthermore, in the parts attribute data table 216 shown in FIG. 44, thepart code P is entered and the name of the supplier-manufacturer and thename of the parts manufacturer are registered or altered.

In this manner, the registration processing of all the basic data iscompleted in the data register means XA. Then, parts demand quantitysetting in the parts demand setting means XB is carried out.

This parts demand setting means XB comprises an assured sales quantitysetting routine 217 and a parts demand calculating routine 218.

Connected to this assured sales quantity setting routine 217 are aproduct sales data table 219 shown in FIG. 45, said product attributedata table 215 and an assured sales quantity data table 220 shown inFIG. 46.

Stored in the product sales data table 219 are the sales data for eachmonth (36 months in FIG. 45) for each product and the assured salesquantity of the particular product is set using the above data in thesteps shown in the flow chart of FIG. 47.

Thus,

Step 1: Finding the past course of sales data of product A from theproduct sales data table 219

Step 2: Estimating the sales drop time t_(o) of product A from the abovecourse of sales data

Step 3: Comparing the time to with the scheduled drop time t₃ of productA stored in the product attribute data table 215 to take whichever isearlier as t_(o).

Step 4: Evaluating globally the past course of sales data of product Ain the product sales data table 219 and the product classification u ofproduct A, the launching time t₁ of a competitive product, the period ofconcurrent sale t₂ in the product attribute table 215, and said droptime t_(o) and setting the assured sales quantity, e.g. the number ofunits g which can certainly be sold, for a predetermined time periodincluding the current month

Step 5: Registering the assured sales quantity g so set as the assuredsales quantity data of product A in the assured sales quantity datatable 220.

Thus, from the product attributes and the past sales performance of theproduct, the minimum assured sales quantity of the product is estimatedand set and, then, the parts demand quantity is calculated in a partsdemand size calculating routine 218.

Connected to this parts demand size calculating routine 218 are saidassured sales quantity data table 220, product constitution data table214, parts constitution data table 210, and parts processing data table211, as well as a parts demand data table 221 shown in FIG. 48.Therefore, the assured sales quantity data table 220 is first searchedthrough to count the total quantities of parts bearing part code P inthe assured sales quantities of all products and the above productconstitution data table 214, parts constitution data table 210 and partsprocessing data table 211 are sequentially searched through to obtainthe desired parts demand data.

FIG. 49 shows the above data tables substituted by factual values. Withreference to the figure, the method of calculating the parts demandquantity is specifically explained below.

Step 1: The assured sales quantity data table 220 shown in FIG. 49(a) issearched to find that the assured sales quantity of product A is 10units.

Step 2: The product constitution data table 214 shown in FIG. 49(b)indicates that product A consists of 2 units of part code q₁, 3 units ofq₂ and 1 unit of q₃. It is, therefore, calculated that the production of10 units of product A requires 20, 30 and 10 units of q₁, q₂ and q₃parts, respectively.

Step 3-1: The parts constitution data table 210 shown in FIG. 49(c)indicates that part code q₁ consists of 1 unit of daughter part code q₇and one unit of q₈ and that part code q₂ consists of 2 units of daughterpart code q₈ and 1 unit of q₁₀. It is, therefore, calculated that theproduction of 20 units of part code q₁ requires 20 units of part code q₇and 20 units of q₈ and that the production of 30 units of part code q₂requires 60 units of part code q₈ and 30 units of q₁₀.

Step 3-2: It is also found that part code q₁₀ consists of 1 unit ofdaughter part code q₁₂ and 3 units of q₁₃. Therefore, it is calculatedthat the production of 30 units of part code q₁₀ requires 30 units ofpart code q₁₂ and 90 units of q₁₃.

Step 4-1: The parts processing data table 211 shown in FIG. 49(d)indicates that part code q₇ is processed from before-part q₁₁ and,therefore, that the production of 20 units of part code q₇ requires 20units of part code q₁₁.

Step 4-2: It is also seen that part code q₁₂ is processed frombefore-part q₁₁ and, therefore, that the production of 30 units of partcode q₁₂ requires 30 units of part code q₁₁.

FIG. 50 shows the results obtained by searching through the assuredsales quantity data table 220, product constitution data table 214,parts constitution data table 210 and parts processing data table 211 inthe steps 1 through 4 in the above manner. The sum of the requirednumbers of units of each part code necessary for meeting the assuredsales quantities of products A, B and C is the demand quantity shown inFIG. 51.

The processing for parts control in the parts control means XC is nowdescribed.

The parts control means XC comprises a parts order routine 222, a partsacceptance routine 223, a parts release routine 224 and a productplanning routine 225.

Connected to the parts order routine 222 are said parts inventory datatable 208, parts order data table 212, parts demand data table 211,parts constitution data table 210, parts processing data table 211 andparts attribute data table 216, and the control of parts order isperformed in the steps shown in the flow chart of FIG. 52.

Thus,

Step 1: Determining and inputting the order size α of part code P

Step 2: Confirming that P*+Σm+α, i.e. the sum of the S inventory P* ofpart code P stored in the parts inventory data table 208, the totalorder quantity Σm of part code P stored in the parts order data table212 and the order quantity a newly entered in step 1, does not exceedthe parts demand quantity u of part code P in the product demand datatable 221. If it exceeds, i.e. P*+Σm+α>u, the input in step 1 isinvalidated and the processing is completed. Thus, in this case, therewas an excessive order for part code P.

Step 3: Searching through the parts constitution date table 210 and, ifit is found that part code P represents the mother part, confirming thatall the daughter parts for them can be supplied. In the event of evenone daughter part is not available for supply, the input in step 1 isinvalidated and the processing is completed. The above confirmation isperformed as follows. The R inventory and V inventory of thecorresponding daughter part are investigated in the parts inventory datatable 208 and, then, the delivery term data and order data in the partsorder data table 212 are investigated. Then, the delivery term data andorder data for all the mother parts employing the corresponding daughterpart are investigated in the parts order data table 212 the liquidationschedule of the corresponding daughter part is calculated.

Step 4: Searching through the parts processing data table 211. When thepart code P represents after-parts, it is confirmed that thecorresponding before-parts can be supplied. If the supply is infeasible,the input in step 1 is invalidated to terminate the processing. Theabove confirmation is carried out by investigating the R inventory and Vinventory in the parts inventory data table 208, the delivery term andorder size data in the parts order data table 212 and the delivery termand order quantity data of all the after-parts employing thecorresponding before-part in the parts order data table 212.

Step 5: Searching through the parts attribute data table 216 and, wherethere are more than one supplier-manufacturers of part code P,requesting designation of a supplier-manufacturer

Step 6: Inputting that supplier-manufacturer

Step 7: Printing an order sheet

Step 8: Registering the part code, supplier-manufacturer, delivery termand order quantity in the parts order data table 212 to complete theprocessing.

Thus, in the parts order routine 222, an order is placed only afterconfirming that the set order quantity does not cause an excess order oran overstock and that daughter parts or before-parts can be suppliedwhen they exist.

Furthermore, the parts acceptance routine 223 is connected to said partsorder data table 212, parts inventory data table 208, parts release datatable 213, parts constitution data table 210 and parts processing datatable 211 and the parts acceptance processing is performed in the stepsshown in the flow chart of FIG. 53.

Thus,

Step 1: Inputting order no. K and acceptance quantity β

Step 2: Retrieving order quantity m and past acceptance quantity n oforder no. K from the parts order data table 212. If m<n+β, it is judgedthat there was an error and the input in step 1 is invalidated toterminate the processing.

Step 3: Searching through the parts constitution data table 210. If thepart code P stored is the mother part, the V inventory P' of theconstituent daughter part is retrieved from the parts inventory datatable 208 and the total release data Σh is retrieved from the partsrelease data table 213. Then, the total difference between orderquantity and acceptance quantity, that is to say the number of partsalready ordered but not delivered as yet, is retrieved and set as g₁.

Furthermore, the acceptance quantity of all the mother parts employingthe corresponding daughter part is retrieved from the parts order datatable 212 and the total acceptance quantity of the correspondingdaughter part is calculated and set as g₂. Thus, if the mother partshave been accepted, it is deemed that the daughter parts have of coursebeen accepted.

Step 4: If P'+Σh+g₁ <g₂ +β×θ (where θ means the number of thecorresponding daughter parts contained in one unit of the mother part),invalidating the input in step 1 as an error and terminating theprocessing.

Step 5: If P'+Σh<g₂ +β×θ<P'+Σh+g₁, calculating g₂ +β×θ-(P'+Σh) andhaving the result reflected in the acceptance data of the correspondingdaughter part in the parts order data table 212 and similarly in therelease data of the corresponding daughter part in the parts releasedata table 213. In other words, it is so treated that the correspondingdaughter part is accepted once and, then, released.

Step 6: Increasing the acceptance data of order no. K in the parts orderdata table 212 by β to complete the processing.

Connected to the parts release routine 224 are the parts order datatable 212, parts inventory data table 208, parts release data table 213,parts constitution data table 210 and parts attribute data table 216,and parts release processing is performed in the steps shown in the flowchart of FIG. 54.

Thus,

Step 1: Entering part code P and its release quantity γ

Step 2: Finding the current inventory of part code P in the followingsteps (i) through (iii)

(i) Retrieving the R inventory of part code P from the parts inventorydata table 208

(ii) Retrieving the total acceptance quantity Σn of part code P from theparts order data table 212

(iii) Retrieving the total release quantity Σh of part code P from theparts release data table 213

Step 3: If the release quantity γ is larger than the current inventory(P+Σn-Σh), the input in step 1 is invalidated as an error to terminatethe processing.

Step 4: Searching through the parts attribute data table 216 and, ifthere are more than one supplier-manufacturers of part code P,requesting designation of the relevant manufacturer

Step 5: Entering the manufacturer's name

Step 6: Assigning a slip number and registering the part code,manufacturer's name, and release quantity in the parts release datatable 213 to terminate the processing.

Connected to the production plan routine 225 are the productconstitution data table 214, parts inventory data table 208 and partsorder data table 212 as well as a production plan data table 226 shownin FIG. 55, and the registration of the production plan is performed inthe steps shown in the flow chart of FIG. 56.

Stored in said production plan data table 226 are the productionschedule and production quantity data for respective product items.

Thus,

Step 1: Entering the production schedule d and production quantity w forproduct A in the production plan data table 226

Step 2: Searching through the product constitution data table 214 toextract all the constituent parts of product A and checking to seewhether these parts can be supplied. If any of the parts is unavailable,the input in step 1 is invalidated to terminate the processing. Theabove checking is done as follows. The R inventory of the particularpart is checked in the parts inventory data table 208 and the deliveryterm and order quantity data in the parts order data table 212 are alsochecked. Then, with regard to other product items which employ thecorresponding constituent part, the production schedule and quantity arechecked in the production plan data table 226 and the liquidationschedule for the corresponding part is calculated. Thus, it is checkedhere whether this constituent part will be available in a sufficientquantity for the production of product A.

Step 3: Registering product name A, production schedule d and productionquantity w in the production plan data table 226 to complete theprocessing.

What is claimed is:
 1. A raw materials ordering system comprising:aproduction quantity determining unit for determining a productionquantity of goods to be manufactured; an order quantity determining unitoperatively connected to the production quantity determining unit andreceiving the production quantity from the production quantitydetermining unit, the order quantity determining unit determining, basedon the production quantity of goods, required quantities of rawmaterials required for manufacturing the production quantity of goodsand determining raw materials order quantities based on both (a) orderbacklog raw materials quantities comprising quantities of raw materialsfor which an order has been sent to a raw materials supplier and the rawmaterials supplier has acknowledged receipt of the order; and (b)in-process raw materials quantities comprising quantities of rawmaterials for which an order has been sent to a raw materials supplierand the raw materials supplier has not acknowledged receipt of the orderor has not confirmed ability to send the raw materials requested.
 2. Araw materials ordering system according to claim 1, wherein the orderquantity determining unit determines raw materials order quantitiesbased on raw materials attribute information, current raw materialsinventory quantities and the required quantities of raw materials.
 3. Araw materials ordering system according to claim 1, further comprising adata input processing unit operatively connected to the order quantitydetermining unit for modifying the required quantities of raw materialsbased on acceptance information confirming receipt of ordered quantitiesof raw materials received from a raw materials supplier and modifyingsaid production quantity based on information concerning quantities offinished goods.
 4. A raw materials ordering system according to claim 3,wherein the data input processing unit is adapted to modify orderbacklog raw materials quantities based on the acceptance information andorder acknowledgment information received from raw materials suppliersindicating an acknowledgment by a raw materials supplier of an order forraw materials.
 5. A raw materials ordering system according to claim 1,wherein the order quantity determining unit is adapted to modify thein-process raw materials quantities based on order acknowledgmentinformation received from raw materials suppliers indicating anacknowledgment by a raw materials supplier of an order for rawmaterials.
 6. A raw materials ordering system according to claim 1,further comprising a product-classified raw material constitution datatable including information concerning quantities of raw materialsrequired for each unit of each of the goods to be manufactured.
 7. A rawmaterials ordering system according to claim 1, further comprising a rawmaterials required quantity data table including information concerningan amount of each of the raw materials to be used each day.
 8. A rawmaterials ordering system according to claim 1, further comprising a rawmaterials inventory data table including information concerninginventory amounts for each of the raw materials.
 9. A raw materialsordering system according to claim 1, further comprising a raw materialsorder acceptance schedule quantity data table including informationconcerning confirming receipt of ordered quantities of raw materialsfrom a raw materials supplier.
 10. A raw materials ordering systemaccording to claim 1, wherein the order quantity determining unitcomprises a software program executed on a computer and includes aninitial setting routine, a production plan setting routine, a requiredquantity setting routine, a production plan modifying routine a requiredquantity modifying routine and an order size determining routine forflexibly storing changes in flow of raw materials in the raw materialsordering system.
 11. A raw materials ordering system comprising:aproduction quantity determining unit for determining a productionquantity of goods to be manufactured; and an order quantity determiningunit operatively connected to the production quantity determining unitand receiving the production quantity from the production quantitydetermining unit, the order quantity determining unit determining, basedon the production quantity of goods, required quantities of rawmaterials required for manufacturing the production quantity of goodsand determining raw materials order quantities based on at leastin-process order quantities comprising quantities of raw materials forwhich an order has been sent to a raw materials supplier and the rawmaterials supplier has not acknowledged receipt of the order or has notconfirmed ability to send the raw materials requested.
 12. A rawmaterials ordering system according to claim 11, wherein the orderquantity determining unit determines raw materials order quantitiesbased on raw materials attribute information, current raw materialsinventory quantities and the required quantities of raw materials.
 13. Araw materials ordering system according to claim 11, further comprisinga data input processing unit operatively connected to the order quantitydetermining unit for modifying the required quantities of raw materialsbased on acceptance information confirming receipt of ordered quantitiesof raw materials received from a raw materials supplier and modifyingsaid production quantity based on information concerning quantities offinished goods.
 14. A raw materials ordering system according to claim13, wherein the data input processing unit is adapted to modify orderbacklog raw materials quantities based on the acceptance information andorder acknowledgment information received from a raw materials supplierindicating an acknowledgment by the raw materials supplier of an orderfor raw materials and the acceptance information.
 15. A raw materialsordering system according to claim 11, wherein the order quantitydetermining unit is adapted to modify the in-process raw materialsquantities based on order acknowledgment information received from a rawmaterials supplier indicating an acceptance by the raw materialssupplier of an order for raw materials.
 16. A raw materials orderingsystem according to claim 11, further comprising a product-classifiedraw material constitution data table including information concerningquantities of raw materials required for each unit of each of the goodsto be manufactured.
 17. A raw materials ordering system according toclaim 11, further comprising a raw materials required quantity datatable including information concerning an amount of each of the rawmaterials to be used each day.
 18. A raw materials ordering systemaccording to claim 11, further comprising a raw materials inventory datatable including information concerning inventory amounts for each of theraw materials.
 19. A raw materials ordering system according to claim11, further comprising a raw materials order acceptance schedulequantity data table including information concerning confirming receiptof ordered quantities of raw materials from a raw materials supplier.20. A raw materials ordering system according to claim 11, wherein theorder quantity determining unit comprises a software program executed ona computer and includes an initial setting routine, a production plansetting routine, a required quantity setting routine, a production planmodifying routine a required quantity modifying routine and an ordersize determining routine for flexibly storing changes in flow of rawmaterials in the raw materials ordering system.
 21. A method of orderingraw materials comprising the steps of:determining a production quantityof goods to be manufactured; determining required quantities of rawmaterials required for manufacturing the production quantity of goodsdetermined in the step of determining the production quantity of goods;and determining raw materials order quantities based on both (a) orderbacklog raw materials quantities comprising quantities of raw materialsfor which an order has been sent to a raw materials supplier and the rawmaterials supplier has acknowledged receipt of the order; and (b)in-process raw materials quantities comprising quantities of rawmaterials for which an order has been sent to a raw materials supplierand the raw materials supplier has not acknowledged receipt of the orderor has not confirmed ability to send the raw materials requested.
 22. Amethod according to claim 21, further comprising modifying order backlograw materials quantities based on order acknowledgment informationreceived from a raw materials supplier confirming receipt of orderedquantities of raw materials.
 23. A method according to claim 21, furthercomprising modifying the required quantities of raw materials based onacceptance information confirming receipt of ordered quantities of rawmaterials from a raw materials supplier and modifying said productionquantity based on quantities of finished goods.
 24. A method of orderingraw materials comprising the steps of:determining a production quantityof goods to be manufactured; determining required quantities of rawmaterials required for manufacturing the production quantity of goodsdetermined in the step of determining the production quantity of goods;and determining raw materials order quantities based on at leastin-process order quantities comprising quantities of raw materials forwhich an order has been sent to a raw materials supplier and the rawmaterials supplier has not acknowledged receipt of the order or has notconfirmed ability to send the raw materials requested.
 25. A methodaccording to claim 24, further comprising modifying the requiredquantities of raw materials based on acceptance information confirmingreceipt of ordered quantities of raw materials received from a rawmaterials supplier and modifying said production quantity based oninformation concerning quantities of finished goods.
 26. A methodaccording to claim 24, further comprising modifying the in-process rawmaterials quantities based on order acknowledgment information receivedfrom a raw materials supplier indicating an acceptance by the rawmaterials supplier of an order for raw materials.